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powermax

1250

Operator Manual

5-1

Section 5

MAINTENANCE AND PARTS

In this section:

Routine maintenance ...............................................................................................................5-2
Inspect the consumables..........................................................................................................5-3
Controls and indicators.............................................................................................................5-4

Indicator LEDs .................................................................................................................5-4

Basic troubleshooting ...............................................................................................................5-5
System circuit diagram .............................................................................................................5-8
Technical questions ..................................................................................................................5-9
Parts .........................................................................................................................................5-9

Torch parts .......................................................................................................................5-9
Power supply parts ........................................................................................................5-10
Accessories ...................................................................................................................5-10

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Summary of Contents for powermax1250

Page 1: ... 120925 120978 120927 120928 120928 120929 120977 110378 Rev A 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ 15 50ft 4 5 15m 15 25ft 4 5 7 5m 35 50ft 12 15m 6 0 BAR 5 0 4 0 PSI 80 70 50 60 80 AMPS 80 AMPS Plasma Arc Cutting System Operator Manual 803950 Revision 1 powermax1250 ...

Page 2: ...007 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2007 Hypertherm Inc All Rights Reserved Hypertherm Powermax and FineCut are trademarks of Hypertherm Inc and may be registered in the United States and or other countries powermax1250 ...

Page 3: ...ghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 49...

Page 4: ...t to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equi...

Page 5: ...n bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted ...

Page 6: ...e with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or additional warranties but Distribut...

Page 7: ...s based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and maintain insurance in such quantities and types and with coverag...

Page 8: ...électriques peuvent être fatals 1a 3 L électricité statique peut endommager les cartes de circuits imprimés 1a 3 Le vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 6 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles d...

Page 9: ...pt 3 2 Claims 3 2 Contents of box 3 2 Locating the power supply 3 3 Lifting the power supply 3 3 Power connection 3 4 Three phase power cord plug installation 3 4 Single phase power cord 3 5 Power cord installation 3 5 Plug installation 3 5 Grounding 3 6 Extension cords 3 6 Torch installation 3 7 Plasma gas supply 3 9 Additional gas filtration 3 9 Gas supply installation 3 10 T80M torch alignment ...

Page 10: ... operation 4 10 Safety trigger operation 4 10 Attach the work clamp 4 11 Starting a cut from the edge of the workpiece 4 11 Hand torch cutting technique 4 12 Piercing 4 13 Gouging 4 14 Cut charts 4 15 80 amp mechanized shielded consumables 4 15 60 amp mechanized shielded consumables 4 16 40 amp mechanized shielded consumables 4 17 FineCut consumables 4 18 40 amp mechanized unshielded consumables 4...

Page 11: ...TABLE OF CONTENTS 0 viii powermax1250 Operator Manual ...

Page 12: ...ity can damage circuit boards 1 3 Toxic fumes can cause injury or death 1 4 A plasma arc can cause injury and burns 1 5 Arc rays can burn eyes and skin 1 5 Grounding safety 1 6 Compressed gas equipment safety 1 6 Gas cylinders can explode if damaged 1 6 Noise can damage hearing 1 7 Pacemaker and hearing aid operation 1 7 A plasma arc can damage frozen pipes 1 7 Additional safety information 1 7 Wa...

Page 13: ...e the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres bef...

Page 14: ...AN KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the work...

Page 15: ...where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations The air quality level in any relevant workplace depends on site specific variables such as TOXIC FUMES CAN CAUSE INJURY OR DEATH Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of c...

Page 16: ...t your eyes from the arc s ultraviolet and infrared rays Lens Shade Arc Current AWS USA ISO 4850 Up to 100 A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Over 400 A No 14 No 14 ARC RAYS CAN BURN EYES AND SKIN Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing t...

Page 17: ...cted for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is com...

Page 18: ...Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 3 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That H...

Page 19: ...2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ventilat...

Page 20: ... imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 6 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages 1a 6 Le bruit peut provoquer des problèmes aud...

Page 21: ... sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais c...

Page 22: ...uctions du présent manuel et conformément aux codes électriques locaux et nationaux Inspecter fréquemment le cordon d alimentation primaire pour s assurer qu il n est ni endommagé ni fendu Remplacer immédiatement un cordon endommagé Un câble dénudé peut tuer Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Lais...

Page 23: ...ux normes et réglementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualité de l air dans tout lieu de travail dépend des variables propres au site comme Type de table humide sèche sous l eau Composition du matériau fini de la surface et composition des revêtements Volume de matériau enlevé Durée du coupage ou du gougeage Dimensions volume...

Page 24: ...u à 100 A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Plus de 400 A No 14 No 14 LES RAYONS DE L ARC PEUVENT BRÛLER LES YEUX ET LA PEAU Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets les étincelles et le métal brûlant Gants à crispin chaussures et casque de sécurité Vêtements ignifuges couvrant tou...

Page 25: ...ation ou connectée pour utilisation Éviter à tout prix le contact électrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Câble de retour Bien fixer le câble de retour ou de masse à la pièce à couper ou à...

Page 26: ...uits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un médecin avant de s approcher d un lieu où s effectue le coupage ou le gougeage plasma Pour réduire les risques associés aux champs magnétiques Garder loin de soi et du même côté du corps le câble de retour et le faisceau de...

Page 27: ...fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4 2 Utiliser...

Page 28: ...las de circuito 1b 3 Humos tóxicos pueden causar lesiones o muerte 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel 1b 5 Seguridad de toma a tierra 1b 6 Seguridad de los equipos de gas comprimido 1b 6 Los cilindros de gas pueden explotar si están dañados 1b 6 El ruido puede deteriorar la audición 1b 7 Operación de...

Page 29: ... daños en el equipo Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo menos 10 metros del área de corte Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles Nunca corte depósitos que contengan mater...

Page 30: ...Instale este equipo y conéctelo a tierra según el manual de instrucciones y de conformidad con los códigos locales y nacionales Inspeccione el cordón de alimentación primaria con frecuencia para asegurarse de que no esté dañado ni agrietado Si el cordón de alimentación primaria está dañado reemplácelo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha ...

Page 31: ...n el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables específicas al sitio tales como Diseño de mesa mojada seca bajo agua La composición del material el acabado de la superficie y la composición de los recubrimientos Volumen que ...

Page 32: ...mero del cristal Corriente del arco AWS EE UU ISO 4850 Hasta 100A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Más de 400 A No 14 No 14 LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación ultravioleta de alta intensidad por las chispas y por el metal ca...

Page 33: ...s cilindros a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa ...

Page 34: ...LADOS Los campos magnéticos producidos por las elevadas corrientes pueden afectar la operación de marcapasos y de audífonos Las personas que lleven marcapasos y audífonos deberán consultar a un médico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magnéticos Mantenga el cable de trabajo y la manguera de la antorcha a...

Page 35: ...rovocados por la antorcha o el cableado pueden ser fatales Protéjase del electrochoque 3 1 Colóquese guantes aislantes No utilice guantes dañados o mojados 3 2 Aíslese de la pieza de trabajo y de la tierra 3 3 Antes de trabajar en una máquina desconecte el enchufe de entrada o la potencia primaria 4 La inhalación de los humos provenientes del área de corte puede ser nociva para la salud 4 1 Manten...

Page 36: ...ax1250 Operator Manual 2 1 Section 2 SPECIFICATIONS In this section Power supply 2 2 Dimensions and weight 2 3 T80 Torches 2 4 Dimensions 2 5 Symbols and markings 2 6 S mark 2 6 CE mark 2 6 IEC symbols used 2 6 ...

Page 37: ...480 VAC 1PH 30 23 200 208 VAC 3PH 40 28 I1eff I1 X used to determine 230 240 VAC 3PH 36 28 rating of power cord 380 400 415 VAC 3PH 21 16 480 VAC 3PH 17 13 600 VAC 3PH 16 5 13 Power factor U1 Volts AC rms Harmonic power factor Displacement power factor 200 208 VAC 1PH 0 99 0 99 230 240 VAC 1PH 0 99 0 99 480 VAC 1PH 0 91 0 99 200 208 VAC 3PH 0 94 0 99 230 240 VAC 3PH 0 94 0 99 380 400 415 VAC 3PH 0...

Page 38: ...ONS 0 powermax1250 Operator Manual 2 3 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ Dimensions and weight Weight of the power supply without a torch 90 lb 41 kg 23 in 584 mm 10 5 in 267 mm 19 5 in 495 mm ...

Page 39: ...0 mm Maximum capacity 5 8 inch 16 mm Gouging Capability 12 2 pounds 5 5 kg hour metal removal rate on mild steel Weight 7 2 pounds 3 3 kg with 25 ft 7 5 m lead T80 13 9 pounds 6 3 kg with 50 ft 15 m lead 20 6 pounds 9 4 kg wih 75 ft 22 5 m lead 4 5 pounds 2 0 kg with 15 ft 4 5 m lead 8 3 pounds 3 8 kg with 25 ft 7 5 m lead T80M 9 9 pounds 4 5 kg with 35 ft 10 7 m lead 15 0 pounds 6 8 kg with 50 ft...

Page 40: ...1250 Operator Manual 2 5 T80 dimensions 8 9 226 mm 3 9 99 mm 1 5 38 mm 1 00 25 mm 2 25 57 mm Torch dimensions 15 25 387 mm 1 00 25 mm 1 38 35 mm 2 03 52mm 8 203 mm 32 pitch 0 125 3 2 mm width 0 125 3 2 mm height T80M dimensions ...

Page 41: ...near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE mark IEC symbols used The following symbols may appear on the power supply data plate control labels and switches O l Direct Current DC The terminal for ...

Page 42: ...3 5 Grounding 3 6 Extension cords 3 6 Torch installation 3 7 Plasma gas supply 3 9 Additional gas filtration 3 9 Gas supply installation 3 10 T80M torch alignment 3 10 ON OFF pendant connection 3 11 Machine interface connection 3 11 Arc voltage 3 12 Changing XFER start machine motion from dry contact closure to voltage signal 3 14 Driving an industrial isolated input module 3 15 Driving a relay co...

Page 43: ...maged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor OEM If you need additional assistance c...

Page 44: ...e front and back and fan side of the power supply for proper ventilation Hoist Cover in place Approved hoisting strap Keep as vertical as possible Lifting the power supply WARNING The system weighs up to 112 lb 51 kg Always lift the power supply by TWO handles Do not lift the power supply by ONE handle The handle can break resulting in injury and damage ...

Page 45: ... 3PH for CE model Use a line disconnect switch for each power supply so that the operator can turn off the power supply quickly in an emergency Locate the switch so it is easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses rated per local and national electrical codes Three phase power cord plug insta...

Page 46: ...6mm2 3 wire power cord The power cord must be connected by a licensed electrician Single phase power cord not for CE model Power cord installation Strip and prepare the power cord wires as shown below Plug installation The plug must be connected to the power cord by a licensed electrician L1 10 Ground L2 4 102 mm 7 178 mm Route lead through strain relief and tighten Power Switch Ground L1 L2 ...

Page 47: ... requirements Refer to Section 1 Grounding safety Extension Cords Use a cord that is certified by national or local codes The cord should be installed by a licensed electrician Refer to the length requirements listed below Recommended extension cord gauge size AWG mm2 10 ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft 3 m 3 7 5 m 7 5 15 m 15 30 m 30 45 m Standard model Input voltage Phase AWG mm2 AWG mm...

Page 48: ...P 0 powermax1250 Operator Manual 3 7 Torch installation Turn OFF power Remove the power cord from the power receptacle Open the ETR door and route the lead through the end cap OFF ON ETR door End cap 1 2 3 ...

Page 49: ...ck release collar and insert the lead s gas fitting Slide the quick release collar foward to lock in the gas fitting Make sure that the gas fitting is secure Make sure that the red dot on the connector is on top then plug in the electrical connector Close the ETR door Quick Release Collar 4 5 6 7 ...

Page 50: ...upply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Gas supply Powermax1250 Water particle filter Oil filter Oil vapor filter Additional gas filtration Use Hypertherm filter kit part number 128647 when site conditions introduce moisture oil or other particulates into the air line A 3 stage coalescing filtration system as...

Page 51: ... a G1 4 adapter supplied Use liquid pipe sealant on threads The nipple and adapter are in the consumables box located on the left side of the power supply cover 2 Air hose Use an inert gas hose with a 3 8 inch 9 5 mm internal diameter Connect it to the gas fitting installed in step 1 Adjust the air pressure according to the procedure in Section 4 Operation Torch CAUTION Never use Teflon tape when ...

Page 52: ...ble with voltage divider Type Input Output Output Notes Normally open 18VDC Normally open Dry contact Divided arc signal of open circuit voltage at closure when arc transfers 50 1 START terminals Requires 120VAC 1A maximum at dry contact closure to activate machine interface relay or switching device supplied by customer Rear panel 3 4 12 14 5 6 sockets Cable wires Green black Red black Black red ...

Page 53: ...ter All work must be performed following applicable national or local codes 1 Disconnect power from the power supply 2 Remove screws that attach the power supply cover to the chassis Remove the cover 3 Feed the cable through the strain relief shown below at the rear of the power supply WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring ...

Page 54: ...on terminal ends to connect to J15 and J16 Note 120VAC or 24 VAC must be sourced externally Signal Arc voltage torch height control Type Output Notes Full arc voltage No voltage divider 300VDC maximum Signal not available on rear panel connector J15 VDC J16 VDC 5 Tighten the strain relief 6 Replace the cover ...

Page 55: ...on module which has an opto coupler built in Shown below are typical connections for a high side drive arrangement Driving a Relay Coil Notes Customer supplied 24 VDC relay coil 240 ohms Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil Pins 5 and 6 are used only on systems that include the PowermaxEdge cable with voltage divider Move black BLK wire to ground GND an...

Page 56: ...to ground GND and add jumper wire as shown Notes Customer supplied isolated input module Pins 5 and 6 are used only on systems that include the PowermaxEdge cable with voltage divider Start Signal Shield 13 12 14 3 4 6 5 V div V div Isolated input module J19 GND 24VDC BLK YEL RED WHT XFER START BLK J16 J15 ...

Page 57: ... 240 ohms Customer supplied 24 VDC power source Must use a suppression diode 1A 100V such as IN4002 through IN4004 type across the coil Pins 5 and 6 are used only on systems that include the PowermaxEdge cable with voltage divider Start Signal Shield 13 12 14 3 4 6 5 V div V div J19 GND 24VDC BLK YEL RED WHT XFER START 24 VDC J16 J15 ...

Page 58: ...ource Notes Customer supplied isolated input module Customer supplied 24 VDC power source Pins 5 and 6 are used only on systems that include the PowermaxEdge cable with voltage divider Start Signal Shield 13 12 14 3 4 6 5 V div V div 24 VDC Isolated input module J19 GND 24VDC BLK YEL RED WHT XFER START J16 J15 ...

Page 59: ...SETUP 0 3 18 powermax1250 Operator Manual ...

Page 60: ...lded 4 4 FineCut 4 5 Ohmic sensing retaining cap 4 5 Unshielded 4 5 Install the torch consumables 4 7 Set the mode switch 4 8 Set the power switch to ON 4 8 Check the indicator lights 4 8 Adjust the gas pressure and current setting 4 9 Hand torch operation 4 10 Safety trigger operation 4 10 Attach the work clamp 4 11 Starting a cut from the edge of the workpiece 4 11 Hand torch cutting technique 4...

Page 61: ...erator Manual Cut charts 4 15 80 amp mechanized shielded consumables 4 15 60 amp mechanized shielded consumables 4 16 40 amp mechanized shielded consumables 4 17 FineCut consumables 4 18 40 amp mechanized unsheilded consumables 4 19 ...

Page 62: ...reen When illuminated it indicates that there is acceptable gas pressure for torch operation Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed Note The condition must be corrected and power turned OFF and then ON again to clear LED Yellow temperature LED When illuminated indicates that the power supply temperature has exceeded its operating limit Red ...

Page 63: ...25 120926 120977 120927 120928 O ring 058519 Shielded 120929 120931 120928 120929 120932 120928 FineCut O ring 058519 220327 120926 220329 120928 220325 120979 For use with CE systems The 22037 swirl ring is intended for manual cutting with FineCut consumables 40A 60A 80A 30A 50A ...

Page 64: ...Operator Manual 4 5 120930 120932 120928 120930 120927 120928 120928 120925 120926 O ring 058519 Gouging 120977 220059 120928 60A 80A O ring 058519 120926 120925 T80M consumable configurations Shielded 120930 120931 40A 60A 80A ...

Page 65: ...Ohmic sensing retaining cap 220061 Unshielded 40A 60A 80A O ring 058519 120979 120979 120979 120928 120928 120928 220006 220007 120980 120926 120925 In CE countries unshielded consumables may only be used in mechanized torch applications Use an ohmic sensing cap when a compatible torch height controller is installed 30A 50A ...

Page 66: ... INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Make sure power is OFF before changing consumables Install the torch consumables Hand tighten only Retaining cap Nozzle Electrode Swirl ring Shield 1 2 ...

Page 67: ...life Use to gouge or for non transfered arc operation Set the power switch to ON Position the power switch to ON I as shown Check that the POWER ON lamp is illuminated Check the indicator lights AC AC V Check that the remaining indicator lamps are NOT illuminated See Section 5 Maintenance and parts for details Check that the gas pressure LED is illuminated in green 1 2 3 ...

Page 68: ... the current knob to gas test Pull the regulator knob to unlock 6 0 BAR 5 0 4 0 PSI 80 70 50 60 AMPS 60 40 80 25 Set the pressure Cutting 70 75 psig 4 8 5 2 bar Gouging 50 60 psig 3 4 4 1 bar Push the regulator knob to lock Turn the current knob away from gas test to stop the gas flow 25 amps minimum 1 2 3 4 5 ...

Page 69: ...N CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Keep away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others Never use with Pendant Switch 1 2 3 ...

Page 70: ...clamp to the portion that will fall away Starting a cut from the edge of the workpiece Hold the torch nozzle vertical at the edge of the workpiece Start cutting from the edge of the workpiece Pause at the edge until the arc has completely cut through the workpiece Then proceed with the cut Attach the work clamp WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an ...

Page 71: ...e at a vertical position and watch the arc as it cuts along the line Shielded consumables Do not push down on the torch when cutting Lightly drag the torch across the workpiece to maintain a steady cut Pulling the torch through the cut is easier than pushing it To cut thin material reduce the amps until you get the best quality cut For straight line cuts use a straight edge as a guide To cut circl...

Page 72: ... Point the torch away from yourself and others Piercing Hold the torch so that the nozzle is within 1 8 inch 3 mm from the workpiece before firing the torch Fire the torch at an angle to the workpiece then slowly rotate it to an upright position When sparks are exiting from the bottom of the workpiece the arc has pierced through the material When the pierce is complete proceed with the cut ...

Page 73: ... others Gouging Hold the torch so that the nozzle is within 1 16 inch 1 5 mm from the workpiece before firing the torch Hold the torch at a 45 degree angle to the work piece Pull the trigger to obtain a pilot arc Transfer the arc to the work piece Maintain a 45 angle approximately from the workpiece Feed into the gouge NOTE A heat shield is available for added hand and torch protection part number...

Page 74: ...al thickness Maximum travel speeds Optimum travel speeds inches mm ipm mm min ipm mm min 80 134 0 25 3 16 4 8 216 5486 140 3556 136 0 50 1 4 6 4 158 4013 103 2616 139 0 75 3 8 9 5 83 2108 54 1372 142 1 2 12 7 50 1270 33 838 145 NA 5 8 15 9 34 864 22 559 150 3 4 19 0 24 610 16 406 153 1 25 4 14 356 9 229 Arc current Arc voltage Pierce delay Material thickness Maximum travel speeds Optimum travel sp...

Page 75: ...eds inches mm ipm mm min ipm mm min 60 134 0 16 ga 1 5 627 15926 502 12751 134 10 ga 3 4 264 6706 211 5359 138 0 25 1 4 6 4 132 3353 86 2184 141 0 75 3 8 9 5 63 1600 41 1041 141 1 50 1 2 12 7 42 1067 27 686 147 NA 5 8 15 9 31 787 20 508 153 3 4 19 0 22 559 14 356 Stainless steel Aluminum Arc current Arc voltage Pierce delay Material thickness Maximum travel speeds Optimum travel speeds inches mm i...

Page 76: ...n 25 147 0 26 ga 0 5 638 16205 415 10541 148 22 ga 0 8 500 12700 325 8255 149 18 ga 1 3 312 7925 203 5156 152 16 ga 1 5 176 4470 114 2896 40 144 0 25 14 ga 1 9 640 16256 221 5613 146 0 50 10 ga 3 4 151 3835 98 2489 147 0 75 3 16 4 7 97 2464 63 1600 149 1 00 1 4 6 4 74 1880 48 1219 Stainless steel Aluminum Arc current Arc voltage Pierce delay Material thickness Maximum travel speeds Optimum travel ...

Page 77: ...Mild steel Stainless steel Arc current Arc voltage Material thickness Approximate travel speeds inches mm ipm mm min 50 76 10 ga 3 4 90 2286 40 83 10 ga 3 4 50 1270 45 77 12 ga 2 7 120 3048 40 81 12 ga 2 7 70 1778 79 14 ga 1 9 135 3810 79 16 ga 1 5 150 3810 79 18 ga 1 2 150 2540 78 20 ga 0 9 120 2540 30 80 24 ga 0 6 150 3174 Arc current Arc voltage Material thickness Approximate travel speeds inch...

Page 78: ...Mild steel Stainless steel Aluminum Arc current Arc voltage Pierce delay Material thickness Maximum travel speeds Optimum travel speeds inches mm ipm mm min ipm mm min 25 125 0 26 ga 0 5 550 13970 353 8966 128 22 ga 0 8 484 12294 315 8001 130 18 ga 1 3 238 6045 155 3937 131 16 ga 1 5 167 4242 109 2769 40 129 0 25 14 ga 1 9 326 8280 212 5385 Arc current Arc voltage Pierce delay Material thickness M...

Page 79: ...OPERATION 0 4 20 powermax1250 Operator Manual ...

Page 80: ...ARTS In this section Routine maintenance 5 2 Inspect the consumables 5 3 Controls and indicators 5 4 Indicator LEDs 5 4 Basic troubleshooting 5 5 System circuit diagram 5 8 Technical questions 5 9 Parts 5 9 Torch parts 5 9 Power supply parts 5 10 Accessories 5 10 ...

Page 81: ... air pressure or vacuum Replace damaged labels Check torch cap on safety switch observe that red fault LED and yellow torch cap LED illunimate when cap is loosened Check consumables for wear and proper installation Check trigger for damage Check torch body for cracks or exposed wires Each Week 6 Months 3 Months WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maint...

Page 82: ... Maximum pit depth Replace 1 32 inch 0 8 mm Electrode Part Check for Action External surfaces Damage or debris Replace Central bore I D Does electrode slide easily Replace Gas holes Blocked holes Replace Swirl ring External surfaces Damage or wear Replace Dry surface Apply a thin film of Hypertherm grease part number 027055 Torch o ring Max 1 32 inch 0 8 mm ...

Page 83: ...uging Green When illuminated indicates that there is acceptable gas pressure for torch operation Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed Note The condition must be corrected and power turned OFF and then ON again to clear the LED Yellow temperature LED When illuminated indicates that the power supply temperature has exceeded its operating li...

Page 84: ...ected to the power supply 2 2 The incoming gas pressure is too low Set incoming gas pressure to 90 120 psig 6 2 8 3 bar Check that there are no leaks in the gas supply line 2 3 Output gas pressure is set too low for selected mode Adjust gas pressure See Section 4 for pressure settings 3 The power ON low line voltage yellow and fault red LEDs are illuminated 3 1 Line voltage is too low too high or ...

Page 85: ...or repair the work clamp 6 2 The work clamp is not making good metal to metal contact Clean the area where the clamp contacts the workpiece 6 3 The torch is too far away from the workpiece Move the torch head closer to the workpiece and start the torch again See Section 4 Hand torch operation 7 The arc blows out but re ignites when the torch switch is pressed again 7 1 The consumable parts are wor...

Page 86: ...eplace if necessary 9 Cut quality is not good 9 1 Consumables are worn or the torch is being used incorrectly See Inspect the consumables in this section See Section 4 Hand torch operation 10 The power ON green and fault red LEDs are flashing 10 1 Self diagnostic failure System needs repair 11 The power ON green and fault red LEDs are illuminated after power is turned on 11 1 Start signal ON when ...

Page 87: ...MAINTENANCE AND PARTS 0 5 8 powermax1250 Operator Manual AC INPUT FILTER CE UNIT ONLY POWER BOARD ETR WORK LEAD TORCH 40 POSITION RIBBON CABLE CONTROL BOARD System circuit diagram ...

Page 88: ...mbly 75 ft 22 5 m lead 087003 T80M machine torch assembly 15 ft 4 6 m lead 087004 T80M machine torch assembly 25 ft 7 6 m lead 087005 T80M machine torch assembly 35 ft 10 7 m lead 087006 T80M machine torch assembly 50 ft 15 2 m lead 087048 T80M machine torch assembly 75 ft 22 5 m lead 027055 Silicon lubricant 1 4 Oz Tube 015337 NIP 1 4 NPT Qdisc STL Non CE 015145 Adapter 1 4 NPT x G1 4 BSPP RH BRS...

Page 89: ...eel kit 128647 Optional air filtration kit 011092 Replacement filter for optional air filtration kit 011093 Replacement filter element for filter kit 027668 Circle cutting guide deluxe 127102 Circle cutting guide basic 027684 Replacement bushing for circle cutting guide assembly 128145 50 ft 15 m work cable with clamp 023206 CNC machine interface cable with voltage divider 128658 Hand torch heat s...

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